Masonry tie for cavity wall construction

ABSTRACT

A masonry wall tie for anchoring a masonry wall to an inner wall of a cavity wall construction includes a base channel member having a pair of spaced generally parallel side walls and an anchor clip configured for engaging the base channel member. A slot is formed in each of the channel side walls. Each slot has an outwardly-extending lip bordering the slot. The base member is fastened to the outer surface of the inner wall. The anchor clip has a pair of oppositely projecting arms, each of which is seated in one of the slots in the side walls. The length of the slots determines the height adjustment of the anchor clip when engaged with the base channel member. The anchor clip spans the gap between the two walls in the cavity wall construction and the brace of the clip is seated within the mortar joint between the bricks or other masonry units on the outer wall.

[0001] This claims the benefit of U.S. Provisional Application Ser. No. 60/472,605, filed May 22, 2003 and hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

[0002] This invention relates to brick veneer/cavity wall construction and, more particularly, to a device used to anchor the outer wall to the inner wall in a cavity wall system.

[0003] Wall systems having a masonry exterior or outer wall are typically constructed of at least one vertical layer of masonry and at least a second vertical layer of a material forming a back-up system. The back-up system or inner wall may be constructed of lumber or of a concrete masonry unit. A space is often provided in such wall systems (e.g., cavity wall systems) between the brick and back-up system.

[0004] The outer wall and the inner wall are interconnected by wall ties in an effort to provide a completed structure having good rigidity and resistance to wind loading, sagging, and other environmental effects. Typically such wall tie systems include an anchor member mounted to the inner wall and a wire tie coupled to the anchor member and spanning the cavity to be embedded in the outer masonry wall.

[0005] Known wall tie systems suffer many disadvantages and drawbacks in that there is a tendency for the wire tie to fracture or break during installation due to the stresses formed in the wall tie as it is flexed and manipulated. Moreover, the anchors and wire ties tend to fracture or twist out of shape after the construction of the walls due to uneven settling of the inner and outer walls causing the facing wall to be inadequately supported. In addition, a number of agencies have recently expressed serious concern regarding the potential for corrosion and failure of the masonry wall ties due to the exposure of the anchors and wire ties to moisture which is present in the cavity between the back-up wall and the masonry veneer.

[0006] While it is highly desirable to provide for a robust wall tie system to properly anchor the outer wall, the commonly utilized systems require numerous anchor and wire tie sets spaced on the inner and outer walls. While many known wall ties are hugely successful, they require a significant quantity of material which increases with wall size giving rise to increasing costs. The goal of added strength has led to added anchor material further increasing costs.

[0007] Wall ties are well known. But some such wall ties are expensive, and do not operate to adequately increase the strength of the cavity wall structure. A principal object of this invention is to provide an anchor and wire tie arrangement which is robust and economical.

[0008] Another object is to provide a wall tie assembly in which, in one embodiment, an anchor channel extends over a length on the inner wall so as to develop a wall tie of great strength and ease of installation.

[0009] Still another object is to provide a wall tie apparatus which is inexpensive, yet which provides great strength and rigidity during a long service life.

SUMMARY OF THE INVENTION

[0010] This invention addresses these and other problems in the prior art and provides an apparatus which allows for simple installation of the masonry wall tie system and robust support for the outer wall in a more economically efficient manner.

[0011] A masonry wall tie for anchoring a masonry veneer wall to a backup wall of a cavity wall construction according to one embodiment of this invention includes a base channel member having a pair of spaced generally parallel channel side walls and an anchor clip configured for engaging the base channel member. A slot is formed in at least one, and preferably both, channel side walls. Each slot has an outwardly-extending lip that is tapered, flared or beveled for added strength. The slots are aligned generally vertical relative to the masonry veneer wall and face one another. The base member is screwed or otherwise fastened to the outer surface of the backup or inner wall.

[0012] The anchor clip has at least one, and preferably a pair, of oppositely projecting arms, each of which is seated in the slot of a corresponding channel side wall. The anchor clip is engaged with the slots by orienting the arms vertically, placing the arms in the gap between the channel side walls, and rotating the anchor clip ninety-degrees so that the arms enter the slots. The length of the slots offers height adjustment of the anchor clip when engaged with the base channel member.

[0013] The anchor clip spans the cavity between the inner and outer walls in the cavity wall construction and the head portion or brace of the clip is seated within the mortar joint between the bricks or other masonry units on the outer wall. The brace is an elongated loop having a generally rectangular shape that lies generally in the same plane as the arms. The base channel member is fabricated from sheet metal and the anchor clip is formed from metal rod or wire stock.

[0014] As a result of this invention, the base channel member is fabricated from much less expensive and thinner gauge metal while offering greater strength than known systems. Even though the base channel member is made from thinner metal, the outwardly-extending lips bordering the slots provide added strength and a robust, yet economical, solution to the problems associated with known wall tie systems.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

[0016]FIG. 1 is a cross-sectional view of a cavity wall system incorporating an exemplary embodiment of a wall tie of this invention;

[0017]FIG. 2 is perspective view of an anchor clip and a base channel member of the masonry wall tie according to an exemplary embodiment of this invention;

[0018]FIG. 3 is a view similar to FIG. 2 with the clip and anchor channel member coupled together;

[0019]FIG. 4 is a cross-sectional view taken along line 3-3 of FIG. 3; and

[0020]FIG. 5 is a perspective view partially broken away showing the embodiment of FIG. 2 being installed in a cavity wall system.

DESCRIPTION OF THE INVENTION

[0021] Referring to FIG. 1, an exemplary cavity wall 10 is shown and includes a brick veneer outer wall 12 and an inner wall 14. The brick veneer 12 is constructed from a plurality of bricks or blocks 16 arranged in a pattern to construct the wall 12. Each brick 16 is of a substantially rectangular shape having a uniform length, height and depth. The brick veneer 12 is built up by placing one layer 18 of bricks 16 over another layer 18, with the upper layer vertically offset from the lower layer by a distance of approximately one-half the length of a brick 16. Thus, a brick 16 on one layer 18 is positioned directly over the space between two bricks 16, 16 on the layer 18 immediately beneath it or above it. The spaces 20 between adjacent bricks 16 and the spaces 22 between adjacent layers or courses 18, 18 of bricks 16 are filled with mortar 24. Alternatively, the veneer 12 may be stone or other masonry units with mortar 24 in the joints or spaces 20, 22.

[0022] The interior wall 14 includes wood framing 26, dry wall and insulation, weather proofing membrane, flashing (not shown) and an outer sheathing layer 28 as is customary. Of course, other materials may be used. In any event, the building wall is constructed so that there is a small cavity or airspace A between the inner surface of the outer wall 12 and the outer surface of the interior wall 14. The airspace or cavity A between the inner surface of the outer wall 12 and the outer surface of the interior wall 14 is usually at least about one to two inches deep, although the exact dimension may vary depending upon the nature of the construction and local building code requirements. A wall tie assembly, generally shown at 29, spans cavity A to secure the outer masonry wall to the inner wall.

[0023] Referring to FIGS. 2-3, a wall tie assembly 29 comprises a base channel member 30 and an anchor clip 32 according to a presently preferred embodiment of this invention are shown. The base channel member 30 has a generally U-shaped configuration with a pair of spaced channel side walls 34, 34 generally parallel to each other and joined together along a proximal edge by a spine or bite portion 36 of the member 30. The spine 36 has a generally T-shaped flange 38 projecting outwardly at both the top and bottom end of the base channel member 30. As shown generally in FIGS. 4-5, the spine 36 of the base channel member 30 is designed and adapted for being juxtaposed against the outer face of the inner wall 14. In one presently preferred embodiment, the side walls 34 are spaced approximately one-half inch from each other and the lateral dimension of the T-shaped flange 38 is approximately seven-eighths of an inch. The width of the channel side walls 34 is approximately three-fourths of an inch. The base channel member 30 preferably has a material thickness of approximately 20 to 22 gauge and the overall height of the base channel member 30 is approximately six inches. The thickness of the base channel member 30 material in many locales is controlled by applicable building codes and other requirements and is typically required to be 16 to 18 gauge. However, due to the configuration of the base channel member 30 of this invention, thinner material for the member 30 provides for comparable strength and performance of members of thicker material. Moreover, the material thickness should be adjusted to accommodate specific applications (residential, commercial, etc.), environments and other use requirements.

[0024] A pair of spaced holes or apertures 40 are provided in the spine 36 through which mechanical fasteners 42 such as screws, nails, tacks or other devices can be inserted to mount the base channel member 30 on the outer surface of the inner wall 14. Preferably, the base channel member 30 is aligned with one of the studs 26 of the inner wall 14 and the mechanical fastener 42 projects through the sheathing member 28 and into the studs 26 for a secure base channel member 30 attachment.

[0025] The channel side walls 34 are generally mirror images of one another and each include an outwardly turned flange 44 on a terminal or distal edge thereof as shown particularly in FIGS. 2-4. In one presently preferred embodiment, the flange 44 is approximately three-sixteenths of an inch in width and extends the entire height of the channel side wall 34. Advantageously, a slot 46 is formed in each side wall 34 and extends generally parallel to each side wall. Each side wall 34 further includes an outwardly tapered or flared lip 48. In one embodiment, lips 44 project outwardly from an exterior surface of the channel side walls 34 in a generally oval configuration. In one presently preferred embodiment, lips 48 project approximately 0.074 inches outwardly from the side walls 34 and are formed form the material of the side wall 34 vacated or bent to form the slot 46. The dimensions of the lips 48 depend at least in part upon the size of the oval slot 46 from which the lip 48 material is formed. Likewise, the size of the slot 46 depends at least in part upon the size of the anchor clip 32 to be inserted therein. The lips 48 provide significant added strength to the base channel member 30 and the wall tie system 29 according to this invention. While the lips 48 are shown in FIGS. 2-5 as projecting outwardly from the associated side wall 34, other configurations and embodiments are possible within the scope of this invention. Preferably, the slot 46 is bounded, at least partially, by an area of material that has increased depth relative to the remainder of the member 30.

[0026] The opening of each slot 46 is sized and configured to receive and capture therein one of two oppositely projecting arms 50 on the terminal portions of the anchor clip 32. The arms 50 are oriented generally perpendicularly to an adjoining anchor clip leg 52. A leg 52 is connected to a brace 54 portion of the clip 32. In one presently preferred embodiment, the brace 54 of the anchor clip 32 is rectangular and about four inches in length and approximately three-fourths of an inch in width. Preferably, the anchor clip 32 is formed from metal rod or wire stock of 9 gauge stock or about one-eighth inch in diameter and the distance from the clip arms 50 to the brace 54 is about four inches. As previously stated, the slots 46 must be sized and configured to accept the lip arms 50 therein accounting for appropriate tolerances, coatings and other factors.

[0027] In use, the base channel member 30 is mounted to the inner wall 14 of the cavity wall system 10 in a generally vertical orientation and preferably secured to the studs 26 of the inner wall 14. The anchor clip 32 is engaged with the slots 46 by initially orienting the clip arms 50 generally vertically and inserting the clip arms 50 between the channel side walls 34. The anchor clip 32 is then rotated into a generally horizontal orientation as shown in FIGS. 2 and 3 so that the clip arms 50 are inserted into the respective slots 46 in the side walls 34 of the base channel member 30. The length of the slots 46 provide for ready adjustment of the height of the clip 32 relative to the base channel member 30 so that as the outer wall 12 is being constructed, the brace 54 of the clip 32 is inserted atop one of the bricks 16 and embedded in the mortar 24 between adjacent courses 18 of the outer wall 12. As shown in FIGS. 1 and 5, the leg 52 of the clip 32 spans the cavity A between the inner and outer walls 12, 14 and the brace 54 and an adjacent portion of the leg 52 are embedded in the mortar 24 between the brick courses 18. Advantageously, because of the length of the slots 46 in the base channel member 30, the clip 32, when engaged therewith, can readily be inserted between adjacent bricks 16 in a range of different courses 18 (see FIG. 5). In other words, the base channel member 30 does not need to be repositioned on the inner wall 14 for the clip 32 to be embedded between the bricks in upper, lower or intermediate courses 18. This provides significant efficiency and versatility for the wall tie system according to this invention. Moreover, because of the lip 48 surrounding each slot 46, the strength with which the clip 32 and base channel member 30 secures the outer wall 12 to the inner wall 14 is significantly increased while still utilizing a thinner and less expensive material for the base channel member 30. For example, 20 gauge metal can be utilized for the base channel member 30 while providing strength comparable to a 12 gauge material with the associated cost benefits of utilizing a thinner material for the base channel member 30.

[0028] As a result, the wall tie assembly according to this invention provides increased strength, versatility and ease of installation with lower material costs and associated economic impact over known systems.

[0029] From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof. 

We claim:
 1. A wall tie assembly for securing an outer masonry wall structure to an adjacent inner wall structure, comprising: a base channel member adapted to be mounted to the inner wall structure, said base channel member having at least one side wall joined to a spine adapted to be juxtaposed to the inner wall structure; an elongated slot formed in said at least one side wall; a lip bordering said elongated slot and extending from said at least one side wall; and an anchor clip having a first end adapted to be slidably coupled to said base channel member along said elongated slot and a second end adapted to be coupled to the outer masonry wall structure thereby securing the masonry wall structure to the adjacent inner wall structure.
 2. The wall tie assembly of claim 1 further comprising at least one aperture in said spine, said at least one aperture adapted to receive a fastening member for securing said base channel member to the inner wall structure.
 3. The wall tie assembly of claim 1 further comprising a pair of said side walls spaced from each other.
 4. The wall tie assembly of claim 3 wherein an elongated slot is formed in each of said side walls.
 5. The wall tie assembly of claim 1 wherein said elongated slot extends generally parallel to said at least one side wall.
 6. The wall tie assembly of claim 1 wherein said spine is generally perpendicular to said at least one side wall.
 7. The wall tie assembly of claim 1 wherein said lip is generally perpendicular to said associated side wall.
 8. The wall tie assembly of claim 1 wherein said lip extends generally outwardly from an outer surface of said at least one side wall.
 9. The wall tie assembly of claim 1 wherein said lip has a generally oval configuration.
 10. The wall tie assembly of claim 1 wherein said at least one side wall further comprises an outwardly extending flange along at least a portion of a distal edge of said at least one side wall.
 11. The wall tie assembly of claim 1 wherein said spine further comprises an outwardly extending flange along a top and bottom end of said spine.
 12. The wall tie assembly of claim 1 wherein said anchor clip comprises: at least one outwardly extending clip arm adapted to be inserted into said elongated slot in said at least one side wall and moveable along said elongated slot so as to adjust the position of said anchor clip relative to said base channel member; a leg member coupled to said clip arm at one end thereof; and a brace coupled to said leg member opposite said clip arm and adapted to be embedded in the masonry wall structure.
 13. The wall tie assembly of claim 12 wherein said anchor clip comprises two outwardly and opposite extending clip arms.
 14. The wall tie assembly of claim 12 wherein said brace is rectangularly shaped.
 15. The wall tie assembly of claim 12 wherein said anchor clip is formed from metal wire stock.
 16. The wall tie assembly of claim 1 wherein said base channel member is formed from sheet metal.
 17. A wall tie assembly for securing an outer masonry wall structure to an adjacent inner wall structure, comprising: a base channel member adapted to be mounted to the inner wall structure, said base channel member comprising: (a) a pair of spaced and generally parallel side walls; (b) a spine joining said side walls along at least a portion of a proximal edge of said side walls, said spine being generally perpendicular to each said side wall and further including at least one aperture adapted to receive a fastening member for securing said base channel member to the adjacent inner wall structure; (c) an elongated slot formed in each of said side walls and extending generally parallel to said side walls; (d) an outwardly extending lip bordering said elongated slot in each said side wall and extending generally perpendicular to an outer surface of each said side wall; an anchor clip comprising: (a) a pair of oppositely projecting clip arms each of which is adapted to be inserted into one of said slots in said base channel member and moveable along said elongated slots; (b) a leg member coupled to said clip arms at one end thereof; and (c) a generally rectangular brace coupled to said leg member opposite said clip arms and adapted to be embedded in the outer masonry wall structure to thereby secure the outer masonry wall structure to the adjacent inner wall structure.
 18. A cavity wall construction, comprising: an inner wall having an outer face; an outer wall having an inner face confronting the outer face of the inner wall and generally being parallel to and spaced from the inner wall so as to define a cavity therebetween, said outer wall comprising courses of masonry units held together with mortar; a plurality of wall tie assemblies joining the inner wall to the outer wall, each wall tie assembly comprising: a base channel member mounted to the outer face of the inner wall, said base channel member having at least one side wall joined to a spine along at least a portion of a proximal edge of said at least one side wall; an elongated slot formed in said at least one side wall; a lip bordering said elongated slot and extending from said at least one side wall; and an anchor clip spanning the cavity between said inner and outer walls, said anchor clip having a first end slidably coupled to said base channel member along said elongated slot and a second end embedded in the mortar between adjacent courses of mortar units thereby securing the outer wall to the inner wall.
 19. The cavity wall construction of claim 18 further comprising at least one aperture in said spine, said at least one aperture adapted to receive a fastening member for securing said wall tie to the inner wall structure.
 20. The cavity wall construction of claim 18 further comprising a pair of said side walls spaced from each other.
 21. The cavity wall construction of claim 20 wherein an elongated slot is formed in each of said side walls.
 22. The cavity wall construction of claim 18 wherein said elongated slot extends generally parallel to said at least one side wall.
 23. The cavity wall construction of claim 18 wherein said spine is generally perpendicular to said at least one side wall.
 24. The cavity wall construction of claim 18 wherein said lip is generally perpendicular to said at least one side wall.
 25. The cavity wall construction of claim 18 wherein said lip extends generally outwardly from an outer surface of said at least one side wall.
 26. The cavity wall construction of claim 18 wherein said lip has a generally oval configuration.
 27. The cavity wall construction of claim 18 wherein said at least one side wall further comprises an outwardly extending flange along at least a portion of a distal edge of said at least one side wall.
 28. The cavity wall construction of claim 18 wherein said spine further comprises an outwardly extending flange along a top and bottom end of said spine.
 29. The cavity wall construction of claim 18 wherein said anchor clip comprises: at least one outwardly extending clip arm adapted to be inserted into said elongated slot in said at least one side wall and moveable along said elongated slot so as to adjust the position of said anchor clip relative to said base channel member; a leg member coupled to said clip arm at one end thereof; and a brace coupled to said leg member opposite said clip arm and adapted to be embedded in the outer wall.
 30. The cavity wall construction of claim 29 wherein said tie member comprises two oppositely extending clip arms.
 31. The cavity wall construction of claim 29 wherein said brace is rectangularly shaped.
 32. The cavity wall construction of claim 29 wherein said tie member is formed from metal wire stock.
 33. The cavity wall construction of claim 18 wherein said base channel member is formed from sheet metal. 